Hany,
Pro-Active maintenance could also be called Predictive maintenance.
Predictive Maintenance (PDM) is different from PM in that PM's are generally, clean, replace, lubricate, replace, inspect (using 5 senses)
PDM differs in that it is based on using technology to detect discrepancies in the operation of equipment before you can detect the problem with your senses (sight, sound, touch, smell, taste). The higher up on the P-F curve that you can detect the imminent failure, the more time you have to PLAN a replacement (on your time schedule, not when it finally gives up and fails completely).
Systematic thermographic, vibration monitoring, ultrasonic.... can let you know FAR in advance of when the equipment is going to fail. These technologies can make a huge difference in your maintenance strategy if they are consistently utilized.
As the graphic shows, it starts with a proper design.
Installation plays a huge part, since studies show that most failures are a result of human error. The proper installation can greatly increase the time the equipment will operate before an incipient failure (still functioning, but at a diminished capacity)
If the equipment makes it to the "P" point, (where a component is starting to fail), this is where you can FIRST start to detect it using technology (Viv, thermo, US...)
Once it gets to where you can sense it yourself, it is nearing complete failure, and you are living on borrowed time and luck.
Far better to detect early and change the component when you want to at a natural production down time rather than during an unplanned outage that impacts production.
Hope this helps clear things up some.
Dave Rempel - CMRP
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David Rempel
RELIABILITY PROFESSIONAL
Allied Reliability Group
Houston TX
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Original Message:
Sent: 12-30-2020 02:59 PM
From: Hany Rezekallah
Subject: Preventive versus Pro-active Maintenance
Torbjorn,
Thank you!
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Hany Rezekallah
OCI Iowa Fertilizer Plant
Wever IA
Original Message:
Sent: 12-30-2020 11:49 AM
From: Torbjorn Idhammar
Subject: Preventive versus Pro-active Maintenance
Hany, there is no international standard for terminology in our industry, so you will get a number of opinions. In my experience "Proactive maintenance" is used as a adjective to describe a philosophy or situation in a plant. For example "We believe in proactive maintenance". In my book, proactive maintenance can be done by:
1. Reduce the need for corrective maintenance (alignment, cleaning, lubrication, balancing, good operator practices, precision installation
2. Find corrective maintenance tasks early through good inspections (inspection=predictive mtce=condition monitoring)
3. Use Fixed time replacements since you know the life of components
Traditionally in the US, #3 is often what people mean with preventive maintenance. But, we at IDCON use the perspective that all 3 are included in preventive maintenance, this is also common in Europe. I don't think either perspective is wrong, as long as it matches definitions for corrective maintenance. A common mistake is to include corrective actions that were found during condition monitoring as "PM" (I find a hot motor during Cond. Mon and change it out, the change out is corrective, not preventive), if you do that you have an overlap between preventive maintenance and "Planned and scheduled corrective maintenance" in definitions.
Now, preventive maintenance, we use the definition All repetitive (time based or meter based) actions that can prevent a failure (#2, #3) or find a failure early (#1). In theory "proactive maintenance" is any task done to prevent and find failures early. The PM often refers to the documented tasks we create in our systems, and proactive a more general definitions. But, in theory, very similar terms. Probably easiest to just put and = sign between them :)
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Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC
Original Message:
Sent: 12-30-2020 11:27 AM
From: Hany Rezekallah
Subject: Preventive versus Pro-active Maintenance
Would like to know about the professional difference between Preventive Maintenance and Pro-active Maintenance?
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Hany R
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